Gas valve with electronic valve proving system

ABSTRACT

Valve assemblies may be configured to perform a valve proving test as part of an operational cycle of a combustion appliance coupled to the valve assembly. The valve assembly may include a valve body having a fluid path, first and second valves situated in the fluid path, first and second valve actuators, and a pressure sensor in fluid communication with an intermediate volume of the fluid path between the first and second valves. A valve controller may monitor a measure related to a pressure in the intermediate volume. The valve controller may then output a signal if the measure related to the pressure in the intermediate volume meets and/or exceeds a threshold value, where the threshold value is determined based on a measure related to an initial pressure in the intermediate volume and a known test duration.

RELATED APPLICATIONS

This application is related to U.S. application Ser. No. 13/326,366filed Dec. 15, 2011 and entitled Gas Valve With Electronic Proof ofClosure System, U.S. application Ser. No. 13/326,353 filed Dec. 15, 2011and entitled Gas Valve With Electronic Valve Proving System, U.S.application Ser. No. 13/326,357 filed Dec. 15, 2011 and entitled GasValve with High/Low Gas Pressure Detection, U.S. application Ser. No.13/326,691 filed Dec. 15, 2011 and entitled Gas Valve With Fuel RateMonitor, U.S. application Ser. No. 13/326,355 filed Dec. 15, 2011 andentitled Gas Valve With Overpressure Diagnostics, U.S. application Ser.No. 13/326,358 filed on Dec. 15, 2011 and entitled Gas Valve With ValveLeakage Test, U.S. application Ser. No. 13/326,361 filed on Dec. 15,2011 and entitled Gas Valve With Electronic Cycle Counter, and U.S.application Ser. No. 13/326,523 filed on Dec. 15, 2011 and entitled GasValve With Communication Link, all of which are incorporated byreference in their entireties and for all purposes.

TECHNICAL FIELD

The disclosure relates generally to valves, and more particularly, togas valve assemblies.

BACKGROUND

Valves are commonly used in conjunction with many appliances forregulating the flow of fluid. For example, gas valves are oftenincorporated into gas-fired appliances to regulate the flow of gas to acombustion chamber or burner. Examples of such gas-fired appliances mayinclude, but are not limited to, water heaters, furnaces, boilers,fireplace inserts, stoves, ovens, dryers, grills, deep fryers, or anyother such device where gas control is desired. In such gas-firedappliances, the gas may be ignited by a pilot flame, electronic ignitionsource, or other ignition source, causing combustion of the gas at theburner element producing heat for the appliance. In many cases, inresponse to a control signal from a control device such as a thermostator other controller, the gas valve may be moved between a closedposition, which prevents gas flow, and an open position, which allowsgas flow. In some instances, the gas valve may be a modulating gasvalve, which allows gas to flow at one or more intermediate flow ratesbetween the fully open position and the fully closed position.Additionally or alternatively, valves are used in one or more otherapplications for controlling a flow (e.g., a flow of a fluid such as aliquid or gas, or a flow of other material).

SUMMARY

This disclosure relates generally to valves, and more particularly, togas valve assemblies. In one illustrative but non-limiting example, avalve assembly may be configured for controlling fuel flow to acombustion appliance, where the combustion appliance may cycle on andoff during a sequence of operational cycles. The valve assembly may, insome cases, perform one or more valve proving tests during an operationcycle and/or between operational cycles to help ensure that the one ormore valves properly close.

In one illustrative embodiment, the valve assembly may include a valvebody having an inlet port and an outlet port with a fluid path extendingbetween the inlet port and the outlet port. The valve assembly mayinclude a first valve situated in the fluid path between the inlet portand the outlet port, and a second valve situated in the fluid pathbetween the inlet port and the outlet port downstream of the firstvalve, with an intermediate volume defined between the first valve andthe second valve. First and second valve actuators may be included inthe valve assembly such that the first and second valve actuators may becapable of moving the first and second valves, respectively, between aclosed position that closes the fluid path between the inlet port andthe outlet path, and open position.

The valve assembly may include a pressure sensor in fluid communicationwith the intermediate volume between the first valve and the secondvalve for sensing a measure related to a pressure in the intermediatevolume. A valve controller may be operatively coupled to the first valveactuator, the second valve actuator, and the pressure sensor. In somecases, the valve controller may be configured to identify both the firstvalve and the second valve are in a closed position, identify a measurerelated to a pressure change rate in the pressure sensed by theintermediate volume pressure sensor in the intermediate volume, andidentify a measure that is related to a leakage rate based at least inpart on the measure that is related to the pressure change rate in theintermediate volume and a measure that is related to a volume of theintermediate volume. The valve controller may be further configured tocompare the measure related to the leakage rate to a threshold value,and output an alert signal if the measure related to the leakage ratecrosses the threshold value.

In some instances, the valve controller may be configured to identify apredetermined duration, close both the first valve via the first valveactuator and the second valve via the second valve actuator, andidentify a measure related to an initial pressure in the intermediatevolume of the valve body. A threshold for the valve proving test may bedetermined by the valve controller based at least in part on both themeasure related to the initial pressure and the identified predeterminedduration. The valve controller may then identify a measure that isrelated to the pressure in the intermediate volume during thepredetermined duration and compare the identified measure related to thepressure in the intermediate volume to the determined threshold value,and output an alert signal if the measure related to the pressure in theintermediate volume crosses the threshold value.

In some instances, a method of performing a valve proving test on a gasvalve assembly may include closing both the first valve and the secondvalve, identifying a measure related to a pressure change rate in thepressure sensed by the intermediate volume pressure sensor, andidentifying a measure that is related to a leakage rate based at leastin part on the measure that is related to the pressure change rate inthe intermediate volume and a measure that is related to a volume of theintermediate volume. Then, the method may include comparing the measurerelated to the leakage rate to a threshold value, and outputting analert signal if the measure related to the leakage rate crosses thethreshold value.

The preceding summary is provided to facilitate an understanding of someof the innovative features unique to the present disclosure and is notintended to be a full description. A full appreciation of the disclosurecan be gained by taking the entire specification, claims, drawings, andabstract as a whole.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of thefollowing detailed description of various illustrative embodiments inconnection with the accompanying drawings, in which:

FIG. 1 is a schematic perspective view of an illustrative fluid valveassembly;

FIG. 2 is a schematic first side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 3 is a schematic second side view of the illustrative fluid valveassembly of FIG. 1, where the second side view is from a side oppositethe first side view;

FIG. 4 is a schematic input side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 5 is a schematic output side view of the illustrative fluid valveassembly of FIG. 1;

FIG. 6 is a schematic top view of the illustrative fluid valve assemblyof FIG. 1;

FIG. 7 is a cross-sectional view of the illustrative fluid valveassembly of FIG. 1, taken along line 7-7 of FIG. 4;

FIG. 8 is a cross-sectional view of the illustrative fluid valveassembly of FIG. 1, taken along line 8-8 of FIG. 2;

FIG. 9 is a schematic diagram showing an illustrative fluid valveassembly in communication with a building control system and anappliance control system, where the fluid valve assembly includes adifferential pressure sensor connect to a valve controller;

FIG. 10 is a schematic diagram showing an illustrative fluid valveassembly in communication with a building control system and anappliance control system, where the fluid valve assembly includesmultiple pressure sensors connected to a valve controller;

FIG. 11 is a schematic diagram showing an illustrative schematic of alow gas pressure/high gas pressure limit control;

FIG. 12 is a schematic diagram showing an illustrative schematic valvecontrol and combustion appliance control, where the controls areconnected via a communication link;

FIG. 13 is a schematic diagram showing an illustrative valve control andproof of closure system in conjunction with a combustion appliance;

FIGS. 14-17 are various illustrative schematic depictions of differentmethods for sensing a position and/or state of a valve within anillustrative valve assembly;

FIGS. 18 and 19 are schematic pressure versus time graphs illustratingpressure thresholds;

FIG. 20 is a schematic flow chart of an illustrative method ofperforming a valve proving system test;

FIG. 21 is a schematic flow chart of an illustrative method ofperforming a valve proving system test; and

FIGS. 22A and 22B are schematic flow charts of an illustrative method ofperforming a valve proving system test.

While the disclosure is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit aspects of thedisclosure to the particular illustrative embodiments described. On thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the spirit and scope of the disclosure.

DESCRIPTION

The following description should be read with reference to the drawingswherein like reference numerals indicate like elements throughout theseveral views. The detailed description and drawings show severalillustrative embodiments which are meant to be illustrative of theclaimed disclosure.

Any descriptors such as first, second, third, fourth, fifth, left right,up, down, bottom, top, are not meant to be limiting unless expresslyindicated. Rather, such descriptors may be used to for clarity purposesto indicate how a feature relates to another feature.

Gas valves may be added to fluid path systems supplying fuel and/orfluid to appliances (e.g., burners, etc.) or may be used individually orin different systems. In some instances, gas safety shutoff valves maybe utilized as automatic redundant valves. Redundancy is achieved, andoften times required by regulatory agencies, by placing at least twosafety shutoff valves in series. The aforementioned redundant valves maybe separate valves fitted together in the field and/or valves locatedtogether in a single valve body, these redundant valves are commonlyreferred to as double-block valves. In accordance with this disclosure,these and other gas valves may be fitted to include sensors and/orswitches and/or other mechanical or electronic devices to assist inmonitoring and/or analyzing the operation of the gas valve and/orconnected appliance. The sensors and/or switches may be of theelectromechanical type or the electronic type, or of other types ofsensors and/or switches, as desired.

In some cases, a gas valve assembly may be configured to monitor and/orcontrol various operations including, but not limited to, monitoringfluid flow and/or fluid consumption, electronic cycle counting,overpressure diagnostics, high gas pressure and low gas pressuredetection, valve proving system tests, valve leakage tests, proof ofvalve closure tests, diagnostic communications, and/or any othersuitable operation as desired.

Valve Assembly

FIG. 1 is a schematic perspective view of an illustrative fluid (e.g.,gas, liquid, etc.) valve assembly 10 for controlling fluid flow to acombustion appliance or other similar or different device. In theillustrative embodiment, the gas valve assembly 10 may include a valvebody 12, which may generally be a six sided shape or may take on anyother shape as desired, and may be formed as a single body or may bemultiple pieces connected together. As shown, the valve body 12 maygenerally be a six-sided shape having a first end 12 a, a second end 12b, a top 12 c, a bottom 12 d, a back 12 e and a front 12 f, as depictedin the various views of FIGS. 1-6. The terms top, bottom, back, front,left, and right are relative terms used merely to aid in discussing thedrawings, and are not meant to be limiting in any manner.

The illustrative valve body 12 includes an inlet port 14, an outlet port16 and a fluid path or fluid channel 18 extending between the inlet port14 and the outlet port 16. Further, valve body 12 may include one ormore gas valve ports 20 (e.g., a first valve port 20 a and a secondvalve port 20 b, shown in FIGS. 7 and 8) positioned or situated in thefluid channel 18, one or more fuel or gas valve member(s) sometimesreferred to as valve sealing member(s) 22 moveable within gas valveports 20 (e.g., a first valve sealing member 22 a within first valveport 20 a and a second valve sealing member 22 b within second valveport 20 b, as shown in FIG. 7), one or more pressure sensor assemblies24 (as shown in FIG. 8, for example), one or more position sensors 48,and/or one or more valve controllers 26 (as shown in FIG. 8, forexample) affixed relative to or coupled to the valve body 12 and/or inelectrical communication (e.g., through a wired or wireless connection)with the pressure sensor assemblies 24 and the position sensor(s) 48.

The valve assembly 10 may further include one or more actuators foroperating moving parts therein. For example, the valve assembly 10 mayhave actuators including, but not limited to, one or more stepper motors94 (shown as extending downward from bottom 12 d of valve body 12 inFIG. 1), one or more solenoids 96 (shown as extending upward from top 12c of valve body 12 in FIG. 1), and one or more servo valves 98 (a servovalve 98 is shown as extending upward from top 12 c of valve body 12 inFIG. 1-3, where a second servo valve has been omitted), where the servovalve 98 may be a 3-way auto-servo valve or may be any other type ofservo valve. Other actuators may be utilized, as desired.

In one illustrative embodiment, the one or more solenoids 96 may controlwhether the one or more gas valve ports 20 are open or closed. The oneor more stepper motors 94 may determine the opening size of the gasvalve ports 20 when the corresponding gas valve sealing member 22 isopened by the corresponding solenoid 96. Of course, the one or morestepper motors 94 may not be provided when, for example, the valveassembly 10 is not a “modulating” valve that allows more than oneselectable flow rate to flow through the valve when the valve is open.

As shown, the valve body 12 may include one or more sensors andelectronics compartments 56, which in the illustrative embodiment,extend from back side 12 e as depicted in FIGS. 1, 2 and 4-6. Thesensors and electronics compartments 56 may be coupled to or may beformed integrally with the valve body 12, and may enclose and/or containat least a portion of the valve controllers 26, the pressure sensorsassemblies 24, and/or the electronics required for operation of valveassembly 10 as described herein. Although the compartments 56 may beillustratively depicted as separate structures, the compartments 56 maybe a single structure part of, extending from, and/or coupled to thevalve body 12.

The one or more fluid valve ports 20 may include a first gas valve port20 a and a second gas valve port 20 b situated along and/or incommunication with the fluid channel 18. This is a double-block valvedesign. Within each gas valve port 20, a gas valve sealing member 22 maybe situated in fluid channel 18 and may be positioned (e.g.,concentrically or otherwise) about an axis, rotatable about the axis,longitudinally and axially translatable, rotationally translatable,and/or otherwise selectively movable between a first position (e.g., anopen or closed position) and a second position (e.g., a closed or openposition) within the corresponding valve port 20. Movement of the valvesealing member 22 may open and close the valve port 20.

It is contemplated that valve sealing member 22 may include one or moreof a valve disk 91, a valve stem 92 and/or valve seal 93 for sealingagainst a valve seat 32 situated in fluid channel 18, as best seen inFIGS. 14-17, and/or other similar or dissimilar components facilitatinga seal. Alternatively, or in addition, valve sealing member 22 mayinclude structural features and/or components of a gate valve, adisk-on-seat valve, a ball valve, a butterfly valve and/or any othertype of valve configured to operate from a closed position to an openposition and back to a closed position. An open position of a valvesealing member 22 may be any position that allows fluid to flow throughthe respective gas valve port 20 in which the valve sealing member 22 issituated, and a closed position may be when the valve sealing member 22forms at least a partial seal at the respective valve port 20, such asshown in FIG. 7. Valve sealing member 22 may be operated through anytechnique. For example, valve sealing member 22 may be operated throughutilizing a spring 31, an actuator 30 to effect movement against thespring 31, and in some cases a position sensor 48 to sense a position ofthe valve sealing member 22.

Valve actuator(s) 30 may be any type of actuator configured to operatethe valve sealing member 22 by actuating valve sealing member 22 fromthe closed position to an open position and then back to the closedposition during each of a plurality of operation cycles during alifetime of the gas valve assembly 10 and/or of the actuator 30. In somecases, the valve actuator 30 may be a solenoid actuator (e.g., a firstvalve actuator 30 a and a second valve actuator 30 b, as seen in FIG.7), a hydraulic actuator, magnetic actuators, electric motors, pneumaticactuators, and/or other similar or different types of actuators, asdesired. In the example shown, the valve actuators 30 a, 30 b may beconfigured to selectively move valves or valve sealing members 22 a, 22b of valve ports 20 a, 20 b between a closed position, which closes thefluid channel 18 between the inlet port 14 and the outlet port 16 of thevalve body 12, and an open position. As discussed, the gas valveassembly 10 of FIGS. 1-8 is an example of a gas safety shutoff valve, ordouble-block valve. In some cases, however, it is contemplated that thegas valve assembly 10 may have a single valve sealing member 22 a, orthree or more valve sealing members 22 in series or parallel, asdesired.

In some cases, the valve assembly 10 may include a characterized portdefined between the inlet port 14 and the outlet port 16. Acharacterized port may be any port (e.g., a fluid valve port 20 or otherport or restriction through which the fluid channel 18 may travel) at oracross which an analysis may be performed on a fluid flowingtherethrough. For example, if a flow resistance of a valve port 20 isknown over a range of travel of the valve sealing member 22, the one ofthe one or more gas valve ports 20 may be considered the characterizedport. As such, and in some cases, the characterized port may be a port20 having the valve sealing member 22 configured to be in an openposition and in a closed position. Alternatively, or in addition, acharacterized port may not correspond to the gas valve port 20 havingthe valve sealing member 22. Rather, the characterized port may be anyconstriction or feature across which a pressure drop may be measuredand/or a flow rate may be determined.

Characterized ports may be characterized at various flow rates toidentify a relationship between a pressure drop across the characterizedport and the flow rate through the fluid channel 18. In some cases, thepressure drop may be measured directly with one or more pressure sensors42, 43, 44, and/or 38. In other cases, the pressure drop may be inferredfrom, for example, the current position of the valve member(s). Theseare just some examples. In some cases, the relationship may be stored ina memory 37, such as a RAM, ROM, EEPROM, other volatile or non-volatilememory, or any other suitable memory of the gas valve assembly 10, butthis is not required.

In some cases, the gas valve assembly 10 may include a flow module 28for sensing one or more parameters of a fluid flowing through fluidchannel 18, and in some instances, determining a measure related to agas flow rate of the fluid flowing through the fluid channel 18. Theflow module 28 may include a pressure block or pressure sensor assembly24, a temperature sensor 34, a valve member position sensor 48 and/or avalve controller 26, among other assemblies, sensors, and/or systems forsensing, monitoring, and/or analyzing parameters of a fluid flowingthrough the fluid channel 18, such as can be seen in FIGS. 9 and 10.

It is contemplated that the flow module 28 may utilize any type ofsensor to facilitate determining a measure related to a flow rate of afluid through fluid channel 18, such as a pressure sensor, a flowsensor, a valve position sensor, a temperature sensor, a current sensor,a gas sensor, an oxygen sensor, a CO sensor, a CO₂ sensor, and/or anyother type of sensor, as desired. In one example, the flow module 28,which in some cases may be part of a valve controller 26, may beconfigured to monitor a differential pressure across a characterizedport, and in some cases, a position of one or more valve sealing members22 of the gas valve assembly 10. The information from monitoring may beutilized by the flow module 28 to determine and/or monitor the flow rateof fluid passing through the fluid channel 18. For example, the flowmodule 28 may determine a measure that is related to a gas flow ratethrough the fluid channel 18 based, at least in part, on the measurethat is related to the pressure drop across the characterized port alongwith the pre-stored relationship in the memory 37. In some cases, thecurrent position of one or more valve sealing members 22 of the gasvalve assembly 10 may also be taken into account (e.g. is the valve 30%open, 50% open or 75% open).

In some instances, the flow module 28 may be configured to output theflow rate of fluid passing through the fluid channel 18 to a display ora remote device. In some cases, the flow module 28 may maintain acumulative gas flow amount passing through the fluid channel 18 (e.g.over a time period), if desired. The measure related to a gas flow mayinclude, but is not limited to, a measure of fuel consumption by adevice or appliance that is connected to an outlet port 16 of the gasvalve assembly 10.

It is contemplated that the valve controller or valve control block 26(see, FIG. 8-10) may be physically secured or coupled to, or secured orcoupled relative to, the valve body 12. The valve controller 26 may beconfigured to control and/or monitor a position or state (e.g., an openposition and a closed position) of the valve sealing members 22 of thevalve ports 20 and/or to perform other functions and analyses, asdesired. In some cases, the valve control block 26 may be configured toclose or open the gas valve member(s) or valve sealing member(s) 22 onits own volition, in response to control signals from other systems(e.g., a system level or central building control), and/or in responseto received measures related to sensed pressures upstream, intermediate,and/or downstream of the characterized valve port(s), measures relatedto a sensed differential pressure across the characterized valveport(s), measures related to temperature sensed upstream, intermediate,and/or downstream of the characterized valve port(s), and/or in responseto other measures, as desired.

The memory 37, which in some cases may be part of or in communicationwith the valve controller 26, may be configured to record data relatedto sensed pressures, sensed differential pressures, sensed temperatures,and/or other measures. The valve controller 26 may access these settingsand this data, and in some cases, communicate (e.g., through a wired orwireless communication link 100) the data and/or analyses of the data toother systems (e.g., a system level or central building control) as seenin FIGS. 9 and 10. The memory 37 and/or other memory may be programmedand/or developed to contain software to affect one or more of theconfigurations described herein.

In some instances, the valve controller 26 may be considered a portionof the flow module 28, the flow module 28 may be considered part of thevalve controller 26, or the flow module 28 and valve controller 26 maybe considered separate systems or devices. Illustratively, the valvecontroller 26 may be coupled relative to the valve body 12 and one ormore gas valve ports 20, where the valve controller 26 may be configuredto control a position (e.g., open or closed positions, including variousopen positions) of the valve sealing member 22 within the valve port 20.In some cases, the valve controller 26 may be coupled to and/or be incommunication with local sensors including, but not limited to thepressure sensor assembly 24 (e.g., used for Low Gas/High Gas pressurelimit functions, Valve Proving System tests, etc.), a flow sensor (e.g.,for measuring gas consumption, etc.), a temperature sensor, 34 (e.g., tomonitor temperature of a key component such as an actuator or othercomponent, etc.), a position sensor 48, a current draw sensor (e.g., forsensing the current draw of an actuator or the entire system, etc.), agas sensor, an oxygen sensor, a carbon monoxide (CO) sensor, a carbondioxide (CO₂) sensor, a cycle sensor and/or cycle counter, timers (e.g.,to measure an amount of time to open the valve and/or close the valve),and/or other sensors and assemblies, as desired.

The valve controller 26 may include or may be in communication with oneor more remote sensor inputs for receiving one or more sensed parametersform one or more remotely located sensors located outside of the valvebody 12, the valve ports 20, and/or valve actuators 30. Illustratively,the one or more remote sensors may include, but are not limited to, oneor more of a pressure sensor, a flow sensor, a temperature sensor, aposition sensor, a current draw sensor, a gas sensor, an oxygen sensor,a carbon monoxide (CO) sensor, a carbon dioxide (CO₂) sensor, a cyclesensor and/or cycle counter, and/or one or more other remote sensors.

In the illustrative embodiment of FIG. 8, the valve controller 26 may beconfigured to monitor a differential pressure across a characterizedport. In some instances, the valve controller 26 may monitor adifferential pressure across the fluid valve port 20 and/or monitor ameasure related to a pressure upstream of a fluid valve port 20 (e.g.,first valve port 20 a) and/or a measure related to a pressure downstreamof a fluid valve port 20 (e.g., second valve port 20 b). The valvecontroller 26 may also be configured to monitor an axial position of thevalve sealing member 22 in the valve port 20 (e.g., see FIGS. 14-17). Asa result, the valve controller 26 may determine a flow rate of fluidpassing through the characterized port, where the valve controller 26may determine the flow rate (and sometimes fluid consumption) based, atleast in part, on the monitored differential pressure and/or monitoredupstream and downstream pressures in conjunction with apre-characterized relationship between the pressure drop across thecharacterized port and the flow rate. In some cases, the monitored axialpositioning of the valve sealing member 22 may also be taken intoaccount, particularly when the valve sealing member 22 may assume one ormore intermediate open positions between the fully closed and fullyopened positions. When so provided, the pre-characterized relationshipbetween the pressure drop across the characterized port and the flowrate may depend on the current axial positioning of valve sealing member22.

In some instances, the valve controller 26 may include a determiningblock, which may include a microcontroller 36 or the like, which mayinclude or be in communication with a memory 37, such as a non-volatilememory. Alternatively, or in addition, the determining block (e.g.microcontroller 36) may be coupled to or may be configured within thevalve control block or valve controller 26. The determining block may beconfigured to store and/or monitor one or more parameters, which may beused when determining a measure that is related to a fluid flow ratethrough the fluid channel 18. The determining block (e.g.microcontroller 36) may be configured to use the stored and/or monitoredparameters (e.g. the relationship between a pressure drop across acharacterized port and the flow rate through the fluid channel 18)stored in the memory 37 to help determine a measure that is related to afluid flow rate through the fluid path or the fluid channel 18.

Illustratively, the determining block (e.g. microcontroller 36) may beconfigured to determine and/or monitor a measure (e.g., a flow rate offluid passing through the characterized port or other similar ordifferent measure, as desired) based, at least in part, on stored and/ormonitored measures including, but not limited to, measures related topressure drop across a characterized valve port or other pressurerelated measures upstream and downstream of the characterized valveport(s), a temperature of the fluid flowing through the fluid channel18, and/or a measure related to a current position of the valve sealingmember 22 at the gas valve port 20 or the size of an opening at thecharacterized port. In one example, a determining block (e.g.microcontroller 36) may include non-volatile memory that is configuredto store opening curves of the valve assembly 10, where the openingcurves may characterize, at least in part, a flow rate as a function ofa sensed axial position of valve sealing member 22, and a senseddifferential pressure across a characterized valve port 20 or anotherwise determined pressure at or adjacent a characterized valve port20 (e.g., knowing a set-point of an upstream pneumatic pressure reducingvalve (PRV), as the set-point pressure of the PRV may be substantiallyequal to the pressure at an inlet of the characterized valve port), andmay facilitate determining an instantaneous and/or cumulative fluid(e.g., fuel) flow in the fluid channel 18 and/or consumption by anappliance in fluid communication with the valve assembly 10.

It is contemplated that the determining block (e.g. microcontroller 36)may continuously or non-continuously control, store, and/or monitor aposition (e.g., an axial or rotary position or open/closed state orother position) of the valve sealing member 22 within the valve port 20,monitor a differential pressure across the characterized port, and/ormonitor a temperature upstream and/or downstream of the characterizedport. In addition, the microcontroller 36 may continuously ornon-continuously determine the flow rate of the fluid passing throughthe characterized port, where the microcontroller 36 may be configuredto record in its memory or in another location, an instantaneous flowrate of fluid flowing through the characterized port, a cumulative flowvolume, and/or a determined instantaneous or cumulative (e.g., total)fluid consumption based on the positions of the valve sealing member(s)22 and determined flow rates at an instant of time or over a specifiedor desired time period. In addition, the determining block (e.g.microcontroller 36) may be configured to report out the instantaneousflow rate, cumulative flow volume, total or cumulative fluid consumptionover a given time period, and/or other determination and/or valveassembly conditions. The determining block (e.g. microcontroller 36) mayreport the instantaneous flow rate, cumulative flow rate, total orcumulative consumption of the fluid flowing through the characterizedport, and/or other determination and/or valve assembly conditions to asystem display 52 of an overall system controller 50 (e.g., abuilding/industrial automation system (BAS/IAS) controller), anappliance display 62 of an appliance/system controller 60 where theappliance may be configured to receive the flowing fluid, a displayadjacent gas valve assembly 10, or any other display, device, controllerand/or memory, as desired.

In some instances, the valve controller 26 may include or be incommunication with a valve actuator 30, which in conjunction with thestepper motor 94 or other device is configured to position the valvesealing member 22 in the valve port 20. The valve actuator 30 and/or thestepper motor 94 may be in communication with the microcontroller 36 ofthe valve controller 26, and the microcontroller 36 may be configured tocontrol, monitor, and/or record the position (e.g., axial position,radial position, etc.) of the valve sealing member 22 within the valveport 20 through the valve actuator 30 (e.g., the valve actuator 30 maybe configured to effect the locking (e.g., the valve actuator 30 OFF) orthe unlocking (e.g., the valve actuator 30 ON) of the valve sealingmember 22 in a particular position) and the stepper motor 94 (e.g.,stepper motor 94 may be configured to adjust the position of the valvesealing member 22 when it is not locked in a particular position), orthrough only the stepper motor 94. Alternatively, or in addition, themicrocontroller 36 may be configured to monitor and record the positionof the valve sealing member 22 within the valve port 20 through aconnection with a position sensor 48 or through other means.

The valve controller 26 may include an I/O or communications interface110 with a communication protocol for transmitting data to and/orotherwise communicating with one or more remote device(s) that may belocated remotely from valve assembly 10 (e.g., a combustion applianceincluding controller 60 located remotely from valve assembly 10, aremote display, an electronic access tool or key, and/or other remotedevices). The communications interface 110 may be a wired or wirelesscommunication interface, where the wired or wireless communicationinterface 110 may be configured to be compatible with a predeterminedcommunication bus protocol or other communication protocol. A wired linkmay be low voltage (e.g. 24V, 5V, 3V, etc.), which may reduce certainissues related to line-voltage wiring schemes. Illustratively,communications interface 110, using the predetermined communication busprotocol or other communication protocol, may be configured to outputand/or communicate one or more valve conditions, one or more measuresrelated to valve conditions, one or more conditions related to a fluidflow through the fluid channel 18, and/or one or more diagnosticparameters, conditions or events, to a device located adjacent or remotefrom the valve assembly 10.

In an illustrative example of monitoring parameters sensed by sensors ofor in communication with a valve assembly, the microcontroller 36 of thevalve controller 26 may continuously or non-continuously monitor andrecord the position (e.g., axial position, radial position, etc.) ofvalve sealing member 22 within the valve port 20 through the valveactuator 30 and the stepper motor 94, and the microcontroller 36 mayindicate the sensed and/or monitored position of the valve sealingmember 22 within the valve port 20 as a prescribed position of valvesealing member 22. The prescribed position of the valve sealing member22 may be the position at which the valve sealing member 22 was and/oris to be located, whereas a position of the valve sealing member 22sensed by the position sensor system 48 may be considered an actualposition of the valve sealing member 22 within the valve port 20.

In the example, the valve controller 26 may be configured to performelectronic operational cycle counting or may include an electroniccounter configured to count each operational valve cycle of the valvesealing members 22 during, for example, the lifetime of the gas valveassembly 10 or during some other time period. In some cases, themicroprocessor 36 of the valve controller 26 may be configured tomonitor a total number of operational cycles (e.g., the number of timesthe fuel valve sealing members 22 are operated from a closed position toan open position and back to a closed position) of the valve ports 20and measures related thereto. In some cases, the microprocessor 36 maystore such data in a non-volatile memory, such as the memory 37,sometimes in a tamper proof manner, for record keeping and/or otherpurposes. The microprocessor 36 may monitor the number of cycles of thevalve sealing members 22 in one or more of several different manners.For example, the microprocessor 36 may monitor the number of cycles ofthe valve sealing members 22 by monitoring the number of times the firstmain valve switch 72 and/or the second main valve switch 74 are poweredor, where one or more control signals may be provided to the fuel valveactuator(s) 30 controlling when the fuel valve actuator(s) 30selectively moves (e.g., opens or closes) the valve sealing member(s)22, the microprocessor 36 may monitor the one or more control signals.

The valve controller 26, in some cases, may monitor the main valveswitches 72, 74 by receiving signals directly from a device locatedremotely from the valve assembly 10 on which the main valve switches 72,74 may be located (e.g. see FIGS. 11-12). Switches ((main valve switches72, 74 and safety switch 70 (discussed below)) may be any mechanismcapable of performing a switching function including, but not limitedto, relays, transistors and/or other solid state switches and circuitdevices and/or other switches. The valve controller 26 may include anelectrical port, sometimes separate from a communications interface 110(discussed below), for receiving one or more control signals from thedevice located remotely from valve assembly 10. The one or more controlsignals received via the electrical port may include, but are notlimited to: a first valve port 20 a control signal that, at least inpart, may control the position of the first valve sealing member 22 avia the first valve actuator 30 a, and a second valve port 20 b controlsignal that, at least in part, may control the position of the secondvalve sealing member 22 b via the second valve actuator 30 b.

As an alternative to monitoring control signals, or in addition,microprocessor 36 may monitor the number of cycles of valve sealingmembers 22 by monitoring data from a position sensor 48. For example,microprocessor 36 of valve controller 26 may monitor position sensor 48and record the number of times valve sealing members 22 are in an openposition after being in a closed position and/or the number of timesvalve sealing members 22 are in a closed position after being in an openposition and/or the number of times valve sealing members are operatedfrom a close position to an open position and back to a closed position.These are just some examples. Further, if valve controller 26 isoperating valve sealing members 22, valve controller 26 may monitor thenumber of operational cycles by counting its own control signals sent tovalve actuators 30 and/or stepper motors 94.

The non-volatile memory, which may maintain and/or store the number ofoperational valve cycles, may be positioned directly on, or packagedwith, valve body 12 (e.g., on or within memory of microcontroller 36)and/or may be accessible by the valve controller 26. Such storage,placement, and/or packaging of valve cycle data may allow forreplacement of components in the overall system (e.g., the an appliancecontrol 60, etc.) without losing the valve cycle data. In anillustrative instance, the valve cycle data may be securely stored, suchthat it may not be tampered with. For example, the valve cycle data maybe stored in the memory 37 (e.g., non-volatile memory or other memory)of the valve controller 26 and the valve cycle data and/or other valveassembly 10 data may be password protected.

The microcontroller 36 of valve assembly 10 may be configured to comparea count of a total number of operational cycles of valve sealing members22 to a threshold number of operational cycles. In an instance where thecounted number of operational cycles of the valve sealing member(s) 22 tapproaches, meets, or exceeds the threshold number of cycles, themicrocontroller 36 may initiate a warning and/or request a switch 69 ina limit string 67 to open and thus, remove or cut power to the valveswitches 72, 74 and fuel valve actuator(s) 30. Alternatively, or inaddition, the microcontroller 36 may send a signal to initiate an alarmand/or put the system in a safety lockout, or the microcontroller 36 maybe configured to take other action as desired. Illustratively, themicrocontroller 36 may be configured to prevent fuel valve actuator(s)30 from allowing the valve sealing member(s) 22 to open after the totalnumber of operational cycles meets and/or exceeds the threshold numberof operational cycles. In some instances, the threshold number of cyclesmay be related to the number of cycles for which the valve assembly 10is rated (e.g., a maximum number of cycles before failures might beexpected, etc.) or related to any other benchmark value. In addition,the microcontroller 36 may be configured to perform other diagnosticsbased on analyzing captured operational cycle data, where the otherdiagnostics may include number of cycles, time duration of cycles, andsimilar or different diagnostics, as desired.

In addition to the communication interface 110 being configured tooutput information to a device located adjacent or remote from the valveassembly 10, the communication interface 110 may be configured toreceive one or more inputs from the remote device or an adjacentlypositioned device. Illustrative inputs may include, but are not limitedto: an acknowledgement of reception of one or more of the valveconditions, a user setting, a system setting, a valve command, and/orother similar or dissimilar input.

In some instances, the valve controller 26 may communicate through theI/O interface or communication interface 110 with a remotely locatedoutput block 46, where the output block 46 may display and/or output adetermined measure related to fluid flow rate through the fluid channel18, sometimes along with other data, information and controls sent fromthe valve controller 26 (see, for example, FIGS. 9 and 10). The outputblock 46 may include a display and/or other remote systems, and themicrocontroller 36 may be configured to send measures to a devicecontrol system 60 or building automation system or overall systemcontroller 50 of the output block 46 for further monitoring and/oranalysis. As discussed, the I/O interface may include a wired and/orwireless interface between the valve controller 26 (e.g.,microcontroller 36) and the output block 46 systems (e.g., the buildingautomation system or the overall system controller 50, the combustionappliance management system 60, handheld device, laptop computer, smartphone, etc.), where the connection between the valve controller 26 mayor may not be made with the communication link 100 (e.g., thecommunication link 100 could, but need not be, the one and only onecommunication link).

In an illustrative operation, the valve controller 26 may be utilized ina method for communicating information between the valve assembly 10 anda combustion appliance controller 60, where the combustion appliancecontroller 60 may be associated with a combustion appliance (e.g., adevice separate from, and possibly remotely relative to valve assembly10) for which the valve assembly 10 may control a flow of fuel. Theoperation may include sensing, with one or more sensor (e.g., pressuresensor assembly 24), one or more sensed parameters within the fluidchannel 18 of the valve assembly 10. The sensed parameter may be storedin the memory 37 (e.g., non-volatile memory or other memory) of thevalve controller 26. The valve controller 26 may determine one or morevalve conditions (e.g., a safety event condition or other valvecondition) based on the one or more sensed parameters. For example, thevalve controller 26 may compare the one or more sensed parameters to athreshold parameter to determine one or more valve conditions. If one ormore valve conditions have been determined, the valve controller 26 maybe configured to send information that may be related to the one or moredetermined valve conditions from valve assembly 10 to the combustionappliance controller 60 (or other controller or device) across acommunication link or bus 100 connected to a communications interface110.

In one example, upon receiving one or more determined valve conditions,such as a safety event condition, the combustion appliance controller 60(or other controller or device) may be configured to open the safetyswitch 70, such that power to a valve control signal that is coupled toone or more valve actuators 30 is cut, thereby automatically closing oneor more valve ports 20 (e.g., closing valve sealing member(s) 22 ofvalve port(s) 20). In some cases, the safety switch 70 may be controlledby an algorithm in the combustion appliance controller 60, where anoutput of the algorithm is affected by information passed via thecommunication link 100. Additionally, or in the alternative, otherfeedback signals may affect an output of the algorithm, where the otherfeedback signals may or may not be passed via the communication link 100and may or may not originate from the valve assembly 10.

In other illustrative operations, a low gas pressure/high gas pressureevent may be reported from the valve controller 26 to the combustionappliance controller 60. In response to receiving a reported low gaspressure/high gas pressure event, the combustion appliance controller 60may be configured to open the safety switch 70. Further, in cases wherea proof of closure event is reported to the combustion appliancecontroller 60 prior to ignition of the combustion appliance, an ignitionsequence may not be started. In certain other instances where a ValveProving System (VPS) sequence test is being performed, a combustionappliance controller 60 may use reported results of the VPS sequencetest to make an evaluation. For example, if in the evaluation of the VPStest it were determined that a valve was leaking, the appliancecontroller 60 might be programmed to open safety switch 70, to initiatea safety lockout, to initiate an alarm, and/or to take any other similaror dissimilar measure.

In other scenarios, the valve assembly 10 may be used as a control valveand in that case, the valve controller 26 may send a signal to thecombustion appliance controller 60 indicative of a valve position, andthe combustion appliance controller 60 may respond accordingly. Theseother scenarios, for example, may be applied in parallel positioningsystem applications, low fire switch applications, auxiliary switchapplications, etc. Additionally, it is contemplated that the valvecontroller 26 may interact with remote devices in other similar anddissimilar manners within the spirit of this disclosure.

The pressure block or pressure sensor assembly 24 may be included in theflow module 28, as seen in FIGS. 9 and 10, and/or the pressure sensorassembly 24 may be at least partially separate from the flow module 28.The pressure sensor assembly 24 may be configured to continuously ornon-continuously sense pressure or a measure related to pressureupstream and/or downstream of a characterized port and/or along otherportions of the fluid channel 18. Although the pressure sensor assembly24 may additionally, or alternatively, include a mass or volume flowmeter to measure a flow of fluid through the fluid channel 18, it hasbeen contemplated that such meters may be more expensive and difficultto place within or outside the valve assembly 10; thus, a useful,relatively low cost alternative and/or additional solution may includeplacing the pressure sensors 38, 42, 43, 44 and/or other pressuresensors within, about and/or integrated in the valve body 12 of thevalve assembly 10 to measure the fluid flow through the fluid channel18, the pressures at the input and output ports, and/or other similar ordifferent pressure related measures. The pressure sensors 38, 42, 43, 44may include any type of pressure sensor element. For example, thepressure sensor element(s) may be MEMS (Micro Electro MechanicalSystems) pressure sensors elements or other similar or differentpressure sensor elements such as an absolute pressure sense element, agauge pressure sense element, or other pressure sense element asdesired. Example sense elements may include, but are not limited to,those described in U.S. Pat. Nos. 7,503,221; 7,493,822; 7,216,547;7,082,835; 6,923,069; 6,877,380, and U.S. patent applicationpublications: 2010/0180688; 2010/0064818; 2010/00184324; 2007/0095144;and 2003/0167851, all of which are hereby incorporated by reference.

In some cases, the pressure sensor assembly 24 may include adifferential pressure sensor 38 for measuring a differential pressuredrop across a characterized valve port 20, or across a differentcharacterized port, as seen in FIG. 9. A pressure sensor assembly 24including a differential pressure sensor 38, may be exposed to both afirst pressure 38 a upstream of a characterized valve port and a secondpressure 38 b downstream of the characterized valve port. Thedifferential pressure sensor 38 may send a measure related to the senseddifferential pressure to the microcontroller 36 of the valve controller26, as seen from the diagram of FIG. 9. The microcontroller 36 may beconfigured to monitor the differential pressure across the characterizedport with the differential pressure measures sensed by the differentialpressure sensor 38.

Alternatively, or in addition, an illustrative pressure sensor assembly24 may include one or more first pressure sensors 42 upstream of acharacterized valve port and one or more second pressure sensors 43downstream of the characterized valve port, where the first and secondpressure sensors 42, 43 may be in fluid communication with the fluidchannel 18 and may be configured to sense one or more measures relatedto a pressure upstream and a pressure downstream, respectively, of thecharacterized valve port, as seen in FIG. 10. Where a second valve port(e.g., the second valve port 20 b) may be positioned downstream of afirst characterized valve port (e.g. the first valve port 20 a) andforming an intermediate volume 19 between the first and second valveports, the pressure sensor assembly 24 may include one or more thirdpressure sensors 44 in fluid communication with the intermediate volume19, which may sense one or more measures related to a pressure in theintermediate volume 19. Where two characterized ports are utilized, thefirst pressure sensors 42 may be upstream of both characterized ports,second pressure sensors 43 may be downstream of both characterizedports, and the third pressure sensors 44 may be downstream from thefirst characterized port and upstream from the second characterized, butthis is not required (e.g., first and second pressure sensors 42, 43 maybe used to estimate the pressure drop across the valves). Additionally,or in the alternative, one or more differential pressure sensors 38 maybe utilized to estimate the pressure drop across the first characterizedport and/or the second characterized port. It is further contemplatedthat valve ports 20 may not be characterized ports.

The pressure sensors 42, 43, 44 may be configured to send each of thesensed measure(s) directly to the microcontroller 36. Themicrocontroller 36 may be configured to save the sensed measures and/orrelated information to the memory 37 (e.g., non-volatile memory or othermemory), and may perform one or more analyses on the received sensedmeasures. For example, the microcontroller 36, which may be a portion ofthe flow module 28 and/or the valve controller 26, may determine ameasure that is related to a fluid flow rate through the fluid pathbased, at least in part, on the received sensed measures related topressure upstream of the characterized port and on the received sensedmeasures related to pressure downstream of the characterized port.

Where a valve assembly 10 includes one or more valve ports 20, thepressure sensor assembly 24 may include the first pressure sensor 42positioned upstream of the first valve port 20 a at or downstream of theinlet port 14, as seen in FIG. 11. In addition, or alternatively, thepressure sensor assembly 24 may include a second pressure sensor 43positioned downstream of the second valve port 20 b at or upstream fromthe outlet port 16. The valve assembly 10 may further include one ormore third pressure sensors 44 downstream of the first valve port 20 aand upstream of the second valve port 20 b. The pressure sensors 42, 43,44 may be configured to sense a pressure and/or a measure related to thepressure in the fluid channel 18, and to communicate the sensed measuresto the valve controller 26, which is physically coupled to or positionedwithin the valve body 12. Where multiple pressure sensors 42, 43, 44exist at or near one or more location (e.g., upstream of the valve ports20, intermediate of the valve ports 20, downstream of the valve ports20, etc.) along the fluid channel 18, at least one of the multiplepressure sensors may be configured to sense pressures over a pressuresub-range different from a sub-range over which at least one other ofthe multiple pressure sensors at the location may be configured to sensepressure, but this is not required. In some cases, and as shown in FIG.8, the various pressure sensors may be mounted directly to acorresponding circuit board, such that when the circuit board is mountedto the valve body 12, the pressure sensor is in fluid communication witha corresponding fluid port in the valve body 12.

In some instances, such arrangements of pressure sensors 38, 42, 43, 44within valve assembly 10, along with the connection between the valvecontroller 26 and the pressure sensors 38, 42, 43, 44 may be used toemulate functions of high gas pressure (HGP) and low gas pressure (LGP)switches, which traditionally require wires and further housingsextending to and from and/or attached to the valve body 12. When theelectronics and elements of the valve assembly 10 are configured toemulate LGP/HGP switches, gas-valve wiring connections and interactionsmay be at least partially avoided, eliminated or simplified. In someinstances, such configuration of the valve controller 26 and thepressure sensors 38, 42, 43, 44 may reduce manual operations (e.g.,manually adjusting a mechanical spring or other device of conventionalhigh gas pressure (HGP) and low gas pressure (LGP) switches), and allowfor a more precise fitting with the electronics of the valve assembly10.

In some cases, the pressure sensor assembly 24 may include one or moreabsolute pressure sensors 54 in communication with the microcontroller36. The absolute pressure sensor 54 may sense an atmospheric pressureadjacent the gas valve assembly 10, and may be configured to communicateand transfer data related to the sensed atmospheric pressure to themicrocontroller 36. The microcontroller 36 may take into account theatmospheric pressure from the absolute pressure sensor 54 whendetermining the flow rate of fluid flowing through the characterizedport and/or an estimate of fuel consumption by an attached applianceand/or when determining threshold values. Other sensors may be includedin valve assembly 10, for example, one other type of sensor may be abarometric pressure sensor.

As discussed, the valve assembly 10 and the flow module 28 thereof mayinclude temperature sensor(s) 34, as seen in FIGS. 9-11. The temperaturesensor 34 may be positioned within the valve body 12 so as to be atleast partially exposed to the fluid channel 18 and configured to sensea temperature of a fluid (e.g., gas or liquid) flowing through the fluidchannel 18 and/or any other temperature in the fluid channel 18. Thetemperature sensor 34 may have a first temperature sensor 34 a at leastpartially exposed to the fluid channel 18 upstream of a characterizedvalve port, and/or a second temperature sensor 34 b at least partiallyexposed to the fluid channel 18 downstream of the characterized valveport, as seen in FIGS. 9 and 10. When there is a first valve port and asecond valve port (e.g., valve ports 20 a, 20 b), there may be a thirdtemperature sensor 34 c in fluid communication with intermediate volume19 between the first and second characterized valve ports, if desired.The sensed temperature measure may be used by flow module 28 to, forexample, compensate, correct, or modify a determined measure (e.g., adensity of a fluid) that is related to, for example, a fluid flow rateof fluid flowing through the fluid channel 18, which may help improvethe accuracy of the flow rate calculation. In operation, the temperaturesensor 34 (e.g., any or all of temperatures sensors 34 a, 34 b, 34 c)may communicate a sensed temperature measure directly or indirectly tothe valve controller 26 and/or the memory 37 (e.g., non-volatile memoryor other memory) of the valve controller 26 (e.g., the memory in amicrocontroller 36 or memory in another location) and/or the flow module28. The valve controller 26 may, in turn, utilize the sensed temperatureto help increase the accuracy of a determined flow rate of fluid passingthrough a characterized port and/or increase the accuracy of acalculated fluid and/or fuel consumption quantity, as desired, and storethe calculated flow rate of fluid passing through a characterized portand/or the calculated fluid and/or fuel consumption quantity in thememory 37 (e.g., non-volatile memory or other memory). Additionally, orin the alternative, in some instances the pressure sensors 38, 42, 43,44 may utilize built-in temperature sensors that are used to internallycompensate the pressure sensor over the operating temperature range. Insuch instances, the temperature reading may be accessible at thepressure sensor output (e.g., a digital communication bus) or at anotherlocation.

The flow module 28 of valve assembly 10 may further include a positionsensor system that may be configured to continuously or discontinuouslysense at least one or more of an axial position, a rotary position,and/or a radial position, of the valve sealing member 22 within or aboutthe fluid valve port 20. In some cases, the position sensor system mayinclude more than one position sensors 48, such that each positionsensor 48 may monitor a sub-range of a valve's total travel. Moreover,the position sensor system may be utilized as a proof of closure switchsystem. The position sensor(s) 48 of the position sensor system may besituated or positioned in valve body 12 at or about a valve port 20. Forexample, and in some instances, the position sensor(s) 48 may be fluidlyisolated from the fluid channel 18 (e.g., fluidly isolated from thefluid channel 18 by the valve body 12), and radially spaced from an axisupon which a valve sealing member(s) 22 may axially and/or rotationallytranslate between a closed position and an open position, as seen inFIGS. 14-17.

An illustrative gas valve assembly 10 may include a first valve port 20a and a second valve port 20 b (see FIG. 7), and a first position sensor48 a monitoring the first valve sealing member 22 a and a secondposition sensor 48 b monitoring the second valve sealing member 22 b,where the position sensors 48 a, 48 b may be separate devices or mayshare an enclosure and/or other parts. In the illustrative instance, thefirst position sensor 48 a may be fluidly isolated from the fluidchannel 18 and radially spaced from a first axis of the first valve port20 a, and the second position sensor 48 b may be fluidly isolated fromthe fluid channel 18 and radially spaced from a second axis of secondvalve port 20 b (see FIGS. 14-17).

As discussed above, the position sensor 48 may be configured to detect ameasure that is related to whether the valve sealing member 22 is in anopen or closed position and/or a measure related to an intermediateposition of the valve sealing member 22 within the fluid valve port 20.In one example, the position sensor(s) 48 may be configured to provide aproof of closure (POC) sensor(s) for the valve port(s) 20 (e.g., thefirst valve port 20 a and/or the second valve port 20 b).

Where the valve sealing member(s) 22 have a range of travel (e.g.,rotationally and/or axially) within the valve port(s) 20, the positionsensor(s) 48 may be configured to sense a current position of the valvesealing member(s) 22 anywhere along the range of travel of the valvesealing member(s) 22. The position sensor 48 may then send (e.g.,through electronic or other communication) sensed positioning data ofthe measure related to the position of the valve sealing member 22 tothe determining block and/or microcontroller 36 and/or the memory 37(e.g., non-volatile memory or other memory) of the valve controller 26and/or the flow module 28, where the microcontroller 36 may beconfigured to monitor the axial position of the valve sealing member 22within the valve port 20 through the position sensor system 48.

In some instances, the valve controller 26 may include an electroniccircuit board and/or a wired or wireless communication link 100 mayfacilitate communication between the position sensor(s) 48 and theelectronic circuit board or other device of the valve controller 26. Thevalve controller 26 may be configured to further pass on positioninginformation to remote devices through communication lines (e.g., thecommunication link 100) and/or display positioning data of the valvesealing member 22 on one or more displays 76 attached to the valveassembly 10 and/or the remote devices, as seen in FIG. 13. The valvecontroller 26 may indicate a closed or open position of the valvesealing member 22 or a degree (e.g., 10%, 20%, 30%, etc.) of an openingof the valve sealing member 22 with one or more visual indicators on orcomprising the display(s) 76, as seen in FIG. 13, such as one or morelight emitting diodes (LEDs) acting as a visual indication of a valvestate and/or position, liquid crystal displays (LCDs), a touch screen,other user interfaces and/or any other display interfacing with ordisplaying information to a user.

In some instances, the position sensor system may include one or moreswitches 64 (e.g., a first switch 64 a and a second switch 64 b, wherethe switch(es) 64 may be or may include relays or other switch typessuch as FETs, TRIACS, etc.) having one or more switched signal paths 66and one or more control inputs 68 (e.g., a first control input 68 a anda second control input 68 b), as seen in FIG. 13. Illustratively, oneswitch 64 may be utilized for multiple position sensors 48, or more thanone switch 64 may be utilized for multiple position sensors (e.g., in a1-1 manner or other manner), as desired. The control input 68 may setthe state of the switched signal paths 66 to a first state or a secondstate or another state, as desired. As depicted in FIG. 13, the valvecontroller 26 may be coupled to the position sensor(s) 48, and maycontrol input 68 of switch 64, where both the valve controller 26 andthe position sensors 48 may be isolated from fluid communication withthe fluid channel 18. In some instances, the valve controller 26 may beconfigured to set the state of the switched signal path 66 to the firststate when the first position sensor 48 a senses that a first valve port20 a is not closed or the first valve sealing member 22 a is not in aclosed position, and to a second state when position sensor 48 sensesthat a first valve port 20 a is closed or the first valve sealing member22 a is in a closed position. Similarly, the valve controller 26 may beconfigured to set the state of the switched signal path 66 to the firststate when the second sensor 48 b senses that the second valve port 20 bis not closed or the second valve sealing member 22 b is not in a closedposition, and to a second state when the position sensor 48 senses thata second valve port 20 b is closed or the second valve sealing member 22b is in a closed position. In the alternative, the valve controller 26may be configured to set the state of the switched signal path 66 to thefirst state when at least one of the first and second sensors valveports 20 a, 20 b are not closed or at least one of the first and secondvalve sealing members 22 a, 22 b are not in a closed position, and to asecond state when the position sensor 48 senses that both first andsecond valve ports 20 a, 20 b are closed or both the first and secondvalve sealing members 22 a, 22 b are in closed positions. Similar oridentical or different processes, as desired, may be utilized for eachposition switch 64 and control input 68.

Illustratively, the valve sealing member(s) 22 may include a sensorelement 80, and position sensor(s) 48 may include one or more transduceror field sensors 82. For example, valve sealing member(s) 22 may includea sensor element 80 (e.g., a magnet when using a field sensor 82, aferrous core when using a linear variable differential transformer(LVDT) 84, or other sense element, and/or similar or dissimilarindicators) secured relative to and translatable with valve sealingmember(s) 22. Position sensor(s) 48 may include one or more fieldsensors 82 (e.g., magnetic field sensors, a LVDT 84, Hall Effect sensorsor other similar or dissimilar sensors), as seen in FIGS. 14-15. Fieldsensor 82 may be positioned within valve body 12 or may be positionedexterior to valve body 12 and radially spaced from a longitudinal axisof the valve port(s) 20 and/or the valve sealing member(s) 22. Theposition sensor(s) 48 may be positioned so as to be entirely exterior tothe fluid channel 18. The meaning of entirely exterior of the fluidchannel 18 may include all position sensors 48 and all electronics(e.g., wires, circuit boards) connected to the position sensor(s) 48being exterior to fluid channel 18. Where the position sensor(s) 48includes an LVDT, the LVDT may be positioned concentrically around andradially spaced from the valve sealing member(s) 22, as shown in FIG.15, and/or the axis of LVDT may be spaced radially and parallel from thevalve sealing members 22.

In some cases, a strain gauge 86, as depicted in FIG. 16, or otherelectromechanical sensor may also be utilized to sense a position of thevalve sealing member 22 within an interior of the fluid channel 18 froma position fluidly exterior of the fluid channel 18 by sensing a strainlevel applied by the spring 31 in communication with valve sealingmember 22. Alternatively, or in addition, the valve sealing member(s) 22may include one or more visual indicators 88 (e.g., a light reflector orother visual indicators), and the position sensor(s) 48 may include oneor more optical sensors 90, as seen in FIG. 17, where visual indicatorsmay be any indicators configured to be viewed by optical sensors througha transparent window 87 sealed with an o-ring or seal 89 or throughanother configuration, such that optical sensors 90 may determine atleast whether the valve sealing member(s) 22 is/are in a closed or openposition. Where a visual position indicator 88 is utilized, and in somecases, a user may be able to visually determine when the valve sealingmember(s) 22 is not in a closed position.

As may be inferred from the disclosure, the position sensor 48 may insome instances operate by detecting a position of a valve sealing member22 and/or optionally the valve stem 92 or the like within a valveassembly 10 having a valve body 12, where the valve sealing member 22may be translatable with respect to the valve port 20 of the valve body12 along a translation or longitudinal axis “A” within a valve port 20.In some cases, the sensor element 80, affixed relative to the valvesealing member 22, may be positioned within the interior of the valvebody 12 and may optionally fluidly communicate with the fluid channel18; however, the position sensor 48 may be isolated from the fluidchannel 18 and/or positioned exterior to the valve body 12. In anillustrative embodiment, the valve sealing member 22 may be positionedat a first position within an interior of the valve port 20 alongtranslation axis A. The first position of the valve sealing member 22may be sensed with position sensor 48 by sensing a location of a sensorelement 80 secured relative to the valve sealing member 22 with theposition sensor 48. Then, the position sensor 48 may automatically orupon request and/or continuously or discontinuously, send the sensedlocation and/or open or closed state of the valve sealing member 22 tothe valve controller 26.

It is contemplated that the valve controller 26 may electronicallycalibrate the closed position of the valve sealing member 22 and/or thevalve stem 92. Such a calibration may store the position of the valvesealing member 22 and/or the valve stem 92 when the valve sealing member22 and/or the valve stem 92 is in a known closed position (e.g. such asduring installation of the valve assembly 10). During subsequentoperation, the position of the valve sealing member 22 and/or the valvestem 92 can be compared to the stored position to determine if the valvesealing member 22 and/or the valve stem 92 is in the closed position. Asimilar approach may be used to electronically calibrate other positionsof the valve sealing member 22 and/or the valve stem 92 (e.g. fully openposition, or some intermediate position), as desired.

Valve Proving System Test

The valve controller 26 may be configured to perform an electronic valveproving system (VPS) test on the valve assembly 10, where all orsubstantially all of the structure required for the VPS may beintegrated directly into the valve assembly 10. When so provided, thedirect integration may allow sensors and electronics needed for VPStesting to share a common housing. Alternatively or in addition, the VPStesting may be initiated by the appliance controller 60 (e.g., a burnercontroller).

In an illustrative operation, a VPS test may be performed on a valveassembly 10 that is coupled to a non-switched gas source, or other gassource, that is under a positive pressure during the VPS test to testthe gas valve assembly 10 for leaks. Alternatively, or in addition, VPStests may be performed on valve assemblies 10 in other configurations.

The valve assembly 10 may be in communication with the combustionappliance controller 60 or other device, and may at least partiallycontrol a fuel flow to a combustion appliance through the fluid channel18. Illustratively, the combustion appliance may cycle on and off duringa sequence of operational cycles, where at least some of the operationalcycles may include performing a VPS test prior to and/or after ignitingreceived fuel during the corresponding operational cycle. For example,VPS tests may be performed on each valve port 20 prior to ignitingreceived fuel during a corresponding operational cycle, VPS tests may beperformed on each valve port 20 after a call for heat is satisfied(e.g., at the very end of an operational cycle), or a VPS test may beperformed on a first valve port 20 a prior to igniting received fuelduring a corresponding operational cycle and on a second valve port 20 bafter a call for heat is satisfied. Illustratively, VPS tests may beautomated processes that occur at every, or at least some, operationalcycle(s) (e.g., once the VPS test has been set up by a field installeror at the original equipment manufacturer, the testing may not requirethe end user to participate in any way).

The structural set up of the valve assembly 10 for a VPS test mayinclude the valve controller 26 being in communication with a pressuresensor 44 that may be in fluid communication with the intermediatevolume 19 between the two valve ports 20 (e.g., the first valve port 20a and the second valve port 20 b, as seen in FIG. 8). Where the valvecontroller 26 may be in communication with the pressure sensor 44, thevalve controller 26 may be configured to determine a measure related toa pressure (e.g., an absolute pressure, a gauge pressure, a differentialpressure, and/or other measure) in the intermediate volume 19 duringeach VPS test performed as part of at least some of the operationalcycles of the combustion appliance, or at other times. Alternatively, orin addition, the valve controller 26 may be in communication with one ormore of the inlet pressure sensor 42, the outlet pressure sensor 43,and/or other pressure sensors (e.g., the differential pressure sensor 38and/or other sensors), where the pressure sensors 38, 42, 43 sensemeasures related to the pressure upstream of the first port 20 a anddownstream of the second port 20 b, respectively, and communicate thesensed measures to the valve controller 26. Although pressure sensorsdownstream of the ports (e.g., the pressure sensor(s) 43) may not bedirectly used to determine whether a valve is leaking, the downstreampressure sensor(s) 43 may, in some cases, monitor outlet pressurebefore, during, and/or after leakage tests of the valves and, in somecases, may facilitate determining which valve is leaking if a valveleakage is detected.

Due to the timing of the VPS test(s) before and/or after operationalcycles, or both, the test(s) may be achieved in an amount of timeconsistent with the useful operation of an individual appliance (e.g., ashort amount of time, 10-15 seconds, 5-30 seconds, or a longer amount oftime) which may depend on one or more of the inlet pressure, initialpressure in the intermediate volume 19, size of the intermediate volume19, volume of the appliance combustion chamber, length of time of theappliance pre-purge cycle, firing rate of the appliance burner, theleakage threshold level (e.g., allowed leakage level/rate), etc. In someinstances, a VPS test duration may be fixed and saved in memory of thevalve assembly 10, the combustion appliance, and/or saved in othermemory. For example, a VPS test duration may be fixed in memory of oraccessible by a controller (e.g., the valve controller 26, thecombustion appliance controller 60, or other controller) in a permanentmanner, for a period of time, for a number of cycles, for each VPS testoccurring before the VPS test duration is changed by a user or anautomated system, and/or in any other suitable manner. Illustratively, afixed VPS test duration may be modified by a user in the field byinteracting with the valve controller 26 and/or the combustion appliancecontroller 60.

Fixed VPS test duration or other predetermined duration (e.g., aduration during which pressure may be monitored in the intermediatechamber or other duration) may mitigate or eliminate the need tocalculate a VPS test duration or other predetermined duration based onone or more factors at the time of initial install of a valve assembly10, such as, but not limited to, an expected inlet gas or fuel pressureor an allowed leakage rate. Rather, and in some cases, an installer mayset the fixed duration at a desired duration without performing anycalculations. Additionally or alternatively, when a fixed VPS testduration or other predetermined duration is utilized, an allowed leakagerate (e.g., as set by a standards setting body, a manufacturer, otherentity, an installer or a user) may, in some cases, be adjusted duringthe life of the valve assembly 10 or combustion appliance. In someinstances, the allowed leakage rate may be adjusted by a user byinteracting with the valve controller 26 and/or the combustion appliancecontroller 60.

In some cases, a VPS test duration or other predetermined duration maybe fixed at the time of initial install of a valve assembly 10 by savingthe set VPS test duration or other predetermined duration to the memory37 (e.g., non-volatile memory or other memory) of the valve assembly 10or other memory that may be located remotely, but in communication withthe valve controller 26. Alternatively or in addition, the VPS testduration or other predetermined duration may be stored in memory of thecombustion appliance. During the install of the valve assembly 10, aninstaller may program the VPS test duration or other predeterminedduration in the valve controller 26 and/or the combustion appliancecontroller 60 to a fixed duration for all or substantially all requiredleakage levels and/or for all expected gas or fuel pressures in thefluid channel 18 (e.g., an inlet gas or fuel pressure upstream of thevalve ports 20). In some cases, the VPS test duration or otherpredetermined duration may also be modified later by interacting withthe valve controller 26 at the valve assembly 10 or remote from thevalve assembly 10.

In some cases, one or more VPS thresholds may be programmed into thevalve controller 26. In some cases, one or more VPS thresholds (e.g., afirst and a second VPS sub-test threshold values) may be calculated. Insome cases, the valve controller 26 may be configured to calculate oneor more VPS thresholds based on one or more parameters and, in someinstances, the valve controller 26 may be configured to store the VPSthresholds (e.g., VPS sub-test threshold values or other VPS testthreshold values) in a memory for later use. The one or more parametersthat the valve controller 26 may consider if it is determining a VPStest threshold may include, but are not limited to, a sensed pressure(e.g., a sensed pressure in the intermediate volume, an inlet pressure,or other pressure), a sensed temperature, a max flow rate of the system,a number of ON-OFF cycles operated up to a point in time, a volume ofthe fluid channel 18, a volume of the intermediate volume 19, analtitude of valve assembly 10 (e.g., for calculating and/or estimated anatmospheric pressure at the valve assembly 10 or for other purposes), abarometric pressure, an absolute pressure, a gas type (e.g., density),ANSI requirements, EN requirements, other agency requirements, anallowed VPS test duration, an allowed pressure measuring duration, andhow small of a leak is to be detected (e.g., an allowed leakage rate,etc). Further, in the event that more than two sub-tests are performedas part of the VPS test, the valve controller 26 may utilize morethreshold values than first and second VPS sub-test threshold values, ifdesired.

In some instances, one or more of the VPS thresholds may be determinedor calculated for a VPS test, and may be used each time the VPS test isexecuted. Alternatively, one or more VPS thresholds may be re-determinedor re-calculated before each of one or more VPS tests are executed. Inone illustrative example, one or more VPS thresholds for a VPS test maybe determined from a set VPS duration (e.g., a test duration or aduration less than a test duration), a known volume of the intermediatevolume 19 of the valve (e.g., which may be programmed into the valvecontroller by a user and/or at the manufacturer), a specified leakagelevel sometimes per a safety standard or other standard, and/or ameasure related to gas or fuel pressure provided at the inlet of thevalve. Since the VPS test duration or other predetermined duration, thevolume of the intermediate volume 19, an altitude of the valve assembly10, and the specified leakage level (e.g., an allowed leakage level) maybe known to the valve controller 26 (e.g., saved in memory 37 or othermemory), the valve controller 26 may identify a measure related to a gasor fuel pressure in the fluid channel 18 before, during, or after aparticular VPS test and can then calculate or determine one or more VPSthreshold values for the particular VPS test.

FIGS. 18 and 19 are schematic pressure versus time graphs depictingpressure thresholds for pressure measured in the intermediate volume 19of a valve assembly during a VPS test. FIG. 18 depicts a graph where theintermediate volume is initially pressurized to a high pressure P_(H) attime=0, where the VPS test is testing leakage through the second valveport 20 b and P_(H) may be equal to a pressure upstream of the firstvalve port 20 a or other pressure indicative of a pressurized state inthe intermediate volume 19. Illustratively, the threshold pressure value(P_(THRESHOLD-H)) when the intermediate volume 19 is in a pressurizedstate is at some pressure less than the pressure P_(H). In such apressurized state of the intermediate volume 19, and in one example,P_(THRESHOLD-H) may be calculated from the following illustrativeequation:

P _(THRESHOLD-H) =P _(H)−(dP/dt)*T  (1)

where dP/dt is the allowed change in pressure rate in the intermediatevolume, and T is the predetermined duration over which pressure ismonitored in the intermediate volume during the VPS test. The dP/dtvalue may represent an allowed leakage rate through the second valve,given the intermediate volume of the valve. For example, dP/dt may beproportional to the ratio of the allowed leakage rate to theintermediate volume. Pressure in the intermediate volume during thepredetermined duration T is represented by line 150 in FIG. 18.

In some instances, a pressure warning threshold P_(THRESHOLD-WH) may becalculated from equation (1), where dP/dt is a value that is less thanthe dP/dt that corresponds to the allowed leakage rate, to give a user awarning when the pressure in the intermediate volume 19 may be changingin a manner that indicates there may be a leak in the valve ports 20,but not to the extent that the valve assembly 10 needs to be shut down.Illustratively, a pressure warning threshold may assist in identifyingdegradation of the valve assembly 10 by providing an indication to auser during a VPS test that valve assembly 10 is beginning to leak priorto a VPS test in which operation of the valve assembly 10 needs to beshut down, as shown in line 160

FIG. 19 depicts a graph where the intermediate volume is initiallypressurized to a pressure P_(L) at time=0, where the VPS test is testingleakage through the first valve port 20 a and P_(L) may be equal to alocal atmospheric pressure or pressure downstream of the second valveport 20 b or other pressure indicative of a depressurized state in theintermediate volume 19. Illustratively, the threshold pressure value(P_(THRESHOLD-L)) when the intermediate volume 19 is in a depressurizedstate is at some pressure greater than the pressure P_(L). In such adepressurized state of the intermediate volume 19, and in one example,P_(THRESHOLD-L) may be calculated from the following illustrativeequation:

P _(THRESHOLD-L) =P _(L)+(dP/dt)*T  (2)

where dP/dt is the allowed change in pressure rate in the intermediatevolume, and T is the predetermined duration over which pressure ismonitored in the intermediate volume during the VPS test. the dP/dtvalue may represent an allowed leakage rate through the first valve,given the intermediate volume of the valve. For example, dP/dt may beproportional to the ratio of the allowed leakage rate to theintermediate volume. Pressure in the intermediate volume during thepredetermined duration T is represented by line 170, in FIG. 19.

In some instances, a pressure warning threshold P_(THRESHOLD-WL) may becalculated from equation (2), where dP/dt is less than the dP/dt thatcorresponds to the allowed leakage rate, to give users a warning whenthe pressure in the intermediate volume 19 may be changing in a mannerthat indicates there may be a leak in the valve ports 20, but not to theextent that the valve assembly needs to be shut down. As discussedabove, a pressure warning threshold may assist in identifyingdegradation of the valve assembly 10 by providing an indication to auser during a VPS test that the valve assembly 10 is beginning to leakprior to a VPS test in which operation of the valve assembly 10 needs tobe shut down, as shown in line 160.

In some cases, the VPS test duration or other predetermined duration maynot be used in calculating the threshold(s) for a VPS test. For example,as an allowed leakage level (e.g., an allowed leakage rate) maytranslate to an allowed rate of pressure change (dP/dt) during a VPStest, the one or more VPS thresholds may be set to be independent of theVPS test duration and may be or may primarily be a function ofatmospheric pressure, allowed leakage rates, and/or a volume size of theintermediate volume 19 of the valve assembly 10.

Illustratively, an equation for an allowed leakage level may be:

Q _(calculated) =dP/dt*V/P _(atm)*3600  (3)

where Q_(calculated) is the measured leakage rate in mass flow volume ofliters/hour, dP/dt is a determined slope of a measured pressure overtime (e.g., a differential pressure) in Pascals/second, V is the volumeof the intermediate volume 19, P_(atm) is the atmospheric pressure inPascals, and 3600 represents the number of seconds in an hour. Althoughparticular units are disclosed, other units may be utilized as desired.The volume of the intermediate volume 19 and the atmospheric pressuremay, generally, be considered constants in this equation. Thus, fromequation (3), an allowed leakage level/rate (provided by a safetystandard or otherwise) may be used as a VPS threshold, and a measuredchange of pressure in the intermediate volume over time (dP/dt) may beentered into equation (3) to obtain Q_(calculated), which may becompared to the VPS threshold value to determine whether the valveassembly 10 passes the VPS test.

Alternatively, or in addition, a VPS threshold may be a change ofpressure over time (dP/dt) determined from equation (3), whereQ_(calculated) is equal to an allowed leakage level and dP/dt is solvedfor by the controller 26 to determine the VPS threshold value. Then, ameasured change of pressure in the intermediate volume over time may bedirectly compared to the determined VPS threshold value to determine ifthe valve assembly 10 passes the VPS test.

In some cases, an intermediate pressure, or a measure related thereto,in the intermediate volume may be measured by the inlet pressure sensor42, by the outlet pressure sensor 43, by the intermediate pressuresensor 44, and/or by other sensors. In instances when the intermediatepressure sensor 44 measures a measure related to the intermediatepressure in the intermediate volume 19, the measure related to theinitial pressure may be sensed or identified before both the first valveport 20 a and the second valve port 20 b are closed (e.g., the firstvalve port 20 a may be opened and the second valve port 20 b may beclosed), after both the first valve port 20 a and the second valve port20 b are closed (e.g., the second valve port 20 b is closed and thefirst valve port 20 a is closed after gas or fuel fills the intermediatevolume), or both to allow the gas or fuel to flow into the intermediatevolume 19 adjacent the intermediate pressure sensor 44 and maintain aninlet pressure. When the inlet pressure sensor 42 is used to provide ameasure related to the initial pressure in the fluid channel 18 (e.g.,inlet gas or fuel pressure or some other measure), the measure relatedto the initial pressure may be measured at any time with respect to aVPS test, including, but not limited to, before both the first valveport 20 a and the second valve port 20 b are closed, after both thefirst valve port 20 a and the second valve port 20 b are closed, orboth. When the outlet pressure sensor 43 is used to provide a measurerelated to the initial pressure in the intermediate volume 19, themeasure related to the gas or fuel pressure in the fluid channel 18 maybe measured when both of the first valve port 20 a and the second valveport 20 b are in an opened position.

Once a VPS test has been initiated by one or more of the valvecontroller 26 and the appliance controller 60, the valve controller 26may determine a threshold value, in a manner similar to as discussedabove, and/or perform one or more other tasks related to the VPS test.For example, after initiating a VPS test, the valve controller 26 mayidentify a predetermined duration associated with the VPS test; measure,sense, or identify a measure related to a fuel pressure (e.g., an inletgas or fuel pressure or other measure) or initial pressure in theintermediate volume 19; and/or determine one or more threshold valuesfor the VPS test (e.g., based on one or more of the identified measurerelated to the fuel pressure or an initial pressure in the intermediatevolume and the identified predetermined duration). The determinedthreshold values may then be saved in memory of or in communication withthe valve controller 26 and used for comparison against an identifiedmeasure related to the pressure in the intermediate volume during theVPS test. In some instances, one or more thresholds (e.g., a firstthreshold, a second threshold, a third threshold, a fourth threshold,and/or one or more other thresholds) may be determined and saved in thememory 37 for use with the current VPS test or sub-tests of the currentVPS test and/or for later use in subsequent VPS tests or sub-tests ofVPS tests.

In an illustrative example, the valve controller 26 may include thememory 37 (e.g., non-volatile memory or other memory) that storespreviously determined first VPS threshold value (e.g., for comparing toa pressure rise in the intermediate volume 19 or elsewhere) and a secondVPS threshold value (e.g., for comparing to a pressure decay in theintermediate volume or elsewhere) utilized in performing a VPS test.Alternatively, or in addition, the memory may be located at a positionother than in the valve controller 26, such as any remote memory thatmay be in communication with the valve controller 26. Such VPSthresholds may be used during subsequent VPS tests, or the VPSthresholds may be recalculated for use during a subsequent VPS test, asdesired.

During a VPS test, a measure that is related to the pressure in theintermediate volume 19 may be measured, determined, and/or identified.In some cases, the measure that is related to the pressure in theintermediate volume 19 may be sensed via a pressure sensor that isexposed to the intermediate volume 19. The valve controller 26 mayfurther be configured to compare the measured, determined, and/oridentified measure related to a pressure in the intermediate volume 19(e.g. an absolute pressure, a gauge pressure, a pressure change rate, orother measure) to a first threshold value during a first valve leakagetest, and/or to compare the measure that is related to a pressure in theintermediate volume 19 (e.g., an absolute pressure, a gauge pressure, apressure change rate, or other measure) to a second threshold valueduring a second valve leakage test. After or while comparing the measurerelated to the pressure in the intermediate volume 19 to one or more ofthe threshold values, the valve controller 26 may output an alert signalor other signal if the measure meets and/or exceeds (e.g., crosses,etc.) the corresponding threshold value

The VPS test may be initiated by commanding the valve actuators 30 toopen and/or close in a desired sequence. This sequence may beinitialized and/or controlled through the valve controller 26 and/orthrough the combustion appliance controller 60. When the VPS test iscontrolled by the valve controller 26, the setup of the VPS settings mayoccur at a display/user interface 76 on board the valve itself or at aremote display (e.g., displays 52, 62 or other displays). When the VPSsequence is initialized and controlled remotely (e.g., remote from thevalve controller 26) through the combustion appliance controller 60, thevalve controller 26 may be configured to detect if the VPS test oranother test is occurring by monitoring gas valve assembly 10 andsignals communicated to and/or from the valve assembly 10.

When the VPS test is to be actuated or initiated at or through thecombustion appliance controller 60, the setup of the VPS settings mayoccur at a remote display (e.g., displays 52, 62 or other display(s)).The valve controller 26 may monitor the valve actuators 30 a, 30 b, afirst control signal (MV1) controlling the first valve actuator 30 a anda second control signal (MV2) controlling the second valve actuator 30b, and/or the states of the valve ports 20 a, 20 b (e.g., by monitoringthe output of the position sensor(s) 48) to identify if the VPS test isoccurring. The first and second control signals (MV1 and MV2) may beactuated by the combustion appliance controller 60 in communication withthe valve assembly 10 or by the valve controller 26 or by a field toolin communication with the valve controller 26 or any other tool orindividual in communication with the valve assembly 10. Although thefield tool and/or other tools may most often be used for actuating thefirst and second control signals (MV1 and MV2) in a valve leakage test,such similar or different tools may be used to operate a VPS test or forsystem level diagnostics and/or troubleshooting by a trained appliancetechnician in the field.

An illustrative method 200 of performing a VPS test, as shown in FIG.20, may include closing 210 both the first valve port 20 a and thesecond valve port 20 b and identifying 212 a measure that is related toa pressure change rate in the pressure sensed by the intermediate volumepressure sensor 44. The method 200 may include identifying 214 a measurerelated to a leakage rate. In one example, the measure related to aleakage rate may be based at least in part on the measure that isrelated to the pressure change rate in the intermediate volume and/or ameasure that is related to the volume of the intermediate volume 19. Themeasure related to the identified leakage rate may be compared 216 to athreshold value (e.g., an allowed leakage rate associated with a safetystandard or other allowed leakage rate). An alert may then be outputted218 if the measure related to the leakage rate meets and/or exceeds(e.g., crosses) the threshold value.

An illustrative method 300 of performing a VPS test, as shown in FIG.21, may include identifying 310 a predetermined duration (e.g., a VPStest duration or a sub-test duration of the VPS test duration programmedinto the valve controller 26 or other test duration) and closing 312 thefirst valve port 20 a and the second valve port 20 b. In the method 300,a measure related to an initial pressure in the intermediate volume 19may be identified 314 and a threshold value may be determined 316. Thethreshold value may be at least partially based on and/or related to oneor more of the identified measure related to the initial pressure in theintermediate volume and the identified predetermined duration. Then, apressure in the intermediate volume 19 of the valve assembly 10 may beidentified 318 at some time after the initial pressure in theintermediate volume is determined and the identified pressure in theintermediate volume 19 may be compared 320 to the determined thresholdvalue. If the pressure in the intermediate volume 19 crosses thedetermined threshold value, the valve controller 26 or other feature ofthe valve assembly may output 322 an alert signal.

In some instances, VPS tests may include performing 410 a first VPSsub-test and performing 440 a second VPS sub-test, as shown in method400 in FIGS. 22A and 22B. In method 400, the valve controller 26 maycause, perform, and/or identify a first predetermined sequence (e.g.,the first VPS test) 410, as shown in FIG. 22A. In performing 410 thefirst VPS sub-test, the first valve actuator 30 a may open 412 the firstvalve port 20 a (if not already opened) and the second valve actuator 30b may then close 414 the second valve port 20 b (if not already closed)to pressurize the intermediate volume 19 between the first valve port 20a and the second valve port 20 b. The first valve actuator 30 b may thenclose 416 the first valve port 20 a to seal the pressurized intermediatevolume 19. In some cases, a predetermined duration associated with thefirst predetermined sequence may be identified 418.

The valve controller 26 may cause, perform and/or identify this firstpredetermined sequence as a first sub-test 410 of a VPS test with theidentified first predetermined duration. While performing the first VPSsub-test, a first measure of an initial pressure in the intermediatevolume 19 may be identified 420 and a first VPS sub-test threshold valuemay be determined 422 (e.g., according to one of the threshold valuedetermining techniques described herein or in another manner).Illustratively, the threshold value may be determined 422 based at leastpartially on one or more of the first measure of the gas pressure andthe identified first test duration. In one or more other instances, thefirst VPS sub-test threshold value may be determined based on one ormore other measures.

A measure related to the pressure (e.g., the pressure or a measurederived therefrom) in the intermediate volume 19 of the valve assemblymay be identified 424 at some time after the initial pressure isidentified and the valve controller 26 may be configured to compare 426the measure that is related to the pressure in the intermediate volume19 (e.g., a pressure, a pressure change rate, or other measure) to thedetermined first VPS sub-test threshold value prior to, during, and/orafter the first sub-set VPS duration. After or while comparing themeasure related to the pressure in the intermediate volume 19 to thefirst sub-test threshold value, the valve controller 26 may output 428 afirst alert signal if the measure meets and/or exceeds (e.g., crosses,etc.) the first sub-test threshold value. The valve controller 26 may beconfigured to output the signal over the communication bus 100 or usinga simple pair of contacts (e.g., relay contacts that close when ameasured pressure surpasses a threshold pressure value) at or incommunication with the appliance controller 60, one or more of a localdisplay, a remote device 50, 60 and/or a remote display 52, 62 of theremote device(s) 50, 60.

The first sub-test of the VPS test may be configured to at least detecta leaking second valve port 20 b. The outputted first alert signal mayindicate, or may cause to be indicated, a valve leakage within the valveassembly 10 (e.g., including an indication of which valve port 20 isleaking) and/or a measure of the magnitude of the valve leakage. If aleak is detected or a first alert signal sent, the valve controller 26,the combustion appliance controller 60, or other controller may disableoperation of the valve assembly 10 in response to the alert signal,where disabling operation of the valve assembly 10 may include closingboth the first valve port 20 a and the second valve port 20 b.

In addition to identifying the first sub-test of a VPS test, the valvecontroller 26 may cause, perform, or identify the following secondpredetermined sequence (e.g., the second VPS test) 440, as shown in themethod 400 of FIG. 22B. In performing the second predetermined sequence440, the second valve actuator 30 b may open 442 the second valve port20 b (if not already opened) and the first valve actuator 30 a may thenclose 444 the first valve port 20 a (if not already closed) todepressurize the intermediate volume 19 between the first valve port 20a and the second valve port 20 b. The second valve actuator 30 a maythen close 446 the second valve port 20 b to seal the depressurizedintermediate volume 19. In some cases, a predetermined durationassociated with the second predetermined sequence may be identified 448.

The valve controller 26 may cause or identify this second predeterminedsequence as a second sub-test of a VPS test with a second predeterminedduration that may be the same or different duration than the firstpredetermined duration. While performing the second VPS sub test, asecond measure of an initial pressure in the intermediate volume 19 maybe identified 450 and a second VPS sub-test threshold value may bedetermined 452 (e.g., according to one of the threshold valuedetermining techniques described herein or in another manner).Illustratively, the second VPS sub-test threshold value may bedetermined based at least partially on one or more of the second measureof the gas pressure and the identified second test duration. In one ormore other instances, the second VPS sub-test threshold value may bedetermined based on one or more other measures.

A measure related to the pressure in the intermediate volume 19 may beidentified 454 or determined by the valve controller 26 at some timeafter identifying the initial pressure and the valve controller 26 maybe configured to compare 456 the identified measure that is related tothe pressure in intermediate volume 19 to the determined second VPSsub-test threshold value (e.g., where the second VPS sub-test thresholdvalue is the same as or different than the first sub-test thresholdvalue) prior to, during, or after a second predetermined duration. Ascontemplated, the first VPS sub-test and the second VPS sub-test of theVPS test may be performed in any order, as desired.

After or while comparing the identified measure related to the pressurein the intermediate volume 19 to the second sub-test threshold value,the valve controller 26 may output 458 a second alert signal if themeasure meets and/or exceeds (e.g., crosses, etc.) the second sub-testthreshold value. The valve controller 26 may be configured to output thesecond alert signal to one or more of a local display, a remote device50, 60 and/or a remote display 52, 62 of the remote device(s) 50, 60.

The second sub-test of the VPS test may be configured to at least detecta leaking first valve port 20 a. Illustratively, the outputted secondalert signal may indicate, or may cause to be indicated, a valve leakagewithin the valve assembly 10 (e.g., which valve port 20 is leaking)and/or a measure of the magnitude of the valve leakage. If a leak isdetected or a second alert signal sent, the valve controller 26, thecombustion appliance controller 60, or other controller may disableoperation of the valve assembly 10 in response to the alert signal,where disabling operation of the valve assembly 10 may include closingboth the first valve port 20 a and the second valve port 20 b.

A VPS test performed on the valve assembly 10 that may be similar to theVPS tests described above may include opening one of the first andsecond valve port 20 a, 20 b with the other of the first and secondvalve ports 20 a, 20 b remaining or being closed. After opening one ofthe first and second valve ports 20 a, 20 b, closing the opened valve toclose both valve ports 20 a, 20 b such that a first initial gas pressuremay be present in intermediate volume 19. An intermediate pressuresensor 44 may continuously or discontinuously sense a pressure in theintermediate volume 19, including the first initial pressure therein,and send the sensed pressures to the valve controller 26. The initialpressure in the intermediate volume 19 may be sensed at any time, forexample, the initial pressure may be sensed after opening one of thevalve ports 20 a, 20 b and before closing that opened valve port 20 a,20 b. The valve controller 26 may monitor (e.g., continuously ordiscontinuously), over time, the pressure in the intermediate volume 19and determine or identify a first measure that is related to a pressurechange rate within the intermediate volume 19 while both of the valveports 20 a, 20 b are in a closed position. After determining oridentifying the first measure that is related to a pressure change ratewithin the intermediate volume 19, the valve controller 26 may comparethe determined first measure related to a pressure change rate in theintermediate volume 19 to a first threshold value stored in the valvecontroller 26. The valve controller 26 may then output to a displayand/or remote device 50, 60 or other device an output signal that isrelated to the first measure related to the pressure change rate (e.g.,a determined pressure change in the intermediate volume 19, or otherdetermined measure), where outputting the output signal may also includestoring the determined first measure related to the pressure change ratein the memory 37 (e.g., non-volatile memory or other memory) on thevalve controller 26. Optionally, the valve controller 26 may output theoutput signal or an alert output signal if the determined or identifiedfirst measure meets and/or exceeds (e.g., crosses, etc.) the firstthreshold value. The output signal, however, may convey any information,as desired. For example, the output signal may convey informationrelated to when (e.g. time stamp) the determined measure that is relatedto the pressure change rate meets and/or exceeds a threshold value, orother information related to or not related to the pressure in theintermediate volume 19. In an alternative, or in addition, to providingthe output signal, a visual and/or audible indicator may be provided toindicate if the valve assembly 10 passed or failed the VPS test.

In addition, or as an alternative, the first and/or second valve port 20a, 20 b may be manipulated such that a second or different initial gaspressure may be present in the intermediate volume 19 while the firstand second valve ports 20 a, 20 b are in the closed position. Forexample, the second valve port 20 b may be closed, then the first valveport 20 a may be opened to pressurize the intermediate volume 19 andthen closed to seal in the second initial pressure. The second initialpressure may be substantially different than the first initial gaspressure, as the first initial pressure may be associated with adepressurized state of the intermediate volume 19 and the second initialpressure may be associated with a pressurized state of the intermediatevolume 19, for example. Similar to above, the intermediate pressuresensor 44 may sense pressure within the intermediate volume 19 andcommunicate the sensed pressure and measures related to the sensedpressures to the valve controller 26. The valve controller 26 maymonitor (e.g., continuously or discontinuously), over time, the pressurein the intermediate volume 19 and determine a second measure that isrelated to a pressure change rate within the intermediate volume 19while both the valve ports 20 a, 20 b are in the closed position.

After determining the second measure that is related to a pressurechange rate within the intermediate volume 19, the valve controller 26may compare the determined second measure related to a pressure changerate in the intermediate volume 19 to a second threshold value stored inthe valve controller 26. The valve controller 26 may then output to adisplay and/or remote device 50, 60 or other device an output signalthat is related to the second measure related to a pressure change rate,where outputting the output signal may also include storing thedetermined second measure related to the pressure change rate in thememory 37 (e.g., non-volatile memory or other memory) on the valvecontroller 26. Optionally, the valve controller 26 may output the outputsignal or a different output signal (e.g., an output signal including analert) if the determined second measure meets and/or exceeds (e.g.,crosses, etc.) the second threshold value. The output signal, however,may convey any information and the outputted signals may be outputted inany situation. Further, the output signal may be configured to provide,or cause to be provided, a visual and/or audible indicator to indicateif the valve assembly 10 passed and/or failed the VPS test.

The steps of the illustrative VPS test may be performed once such aswhen the gas valve assembly 10 is installed or during routinemaintenance, and/or the steps may be repeated during each combustioncycle, or during one or more combustion cycles, of a combustionappliance. In any case, the valve controller 26 or other device, or evena user, may identify a trend in the stored determined measures relatedto the pressure change rate in the intermediate volume 19 or in otherdata sensed, calculated, and/or stored during the valve leakage tests. Adetermined trend may be used for any of many purposes, for example, atrend may be used to predict when the valve will require replacementand/or servicing, and/or to make other predictions. Further, a VPS testand/or leakage test may be initiated and/or operated dependent on orindependent of an attached device (e.g., a combustion appliancecontroller 60). In such an instance, the valve controller 26 may beconfigured to initiate and operate a VPS test and/or leakage testindependent of an attached device and may be configured to disable aheat call or other signal to and/or from an attached device, whenappropriate.

Those skilled in the art will recognize that the present disclosure maybe manifested in a variety of forms other than the specific embodimentsdescribed and contemplated herein. Accordingly, departure in form anddetail may be made without departing from the scope and spirit of thepresent disclosure as described in the appended claims.

What is claimed is:
 1. A valve assembly for controlling fuel flow to acombustion appliance, the valve assembly comprising: a valve body havingan inlet port and an outlet port, with a fluid path extending betweenthe inlet port and the outlet port; a first valve situated in the fluidpath between the inlet port and the outlet port; a second valve situatedin the fluid path between the inlet port and the outlet port downstreamof the first valve, with an intermediate volume between the first valveand the second valve defined by the valve body; a first valve actuator,secured relative to the valve body, for selectively moving the firstvalve between a closed position, which closes the fluid path between theinlet port and the outlet port, and an open position; a second valveactuator, secured relative to the valve body, for selectively moving thesecond valve between a closed position, which closes the fluid pathbetween the inlet port and the outlet port, and an open position; anintermediate pressure sensor in fluid communication with theintermediate volume between the first valve and the second valve forsensing a measure that is related to a pressure in the intermediatevolume; a controller operatively coupled to the first valve actuator,the second valve actuator and the intermediate pressure sensor, thecontroller configured to: identify both the first valve and the secondvalve are in a closed position; identify a measure that is related to apressure change rate in the pressure sensed by the intermediate pressuresensor in the intermediate volume; identifying a measure that is relatedto a leakage rate based at least in part on the measure that is relatedto the pressure change rate in the intermediate volume and a measurethat is related to the volume of the intermediate volume; compare themeasure related to the leakage rate to a threshold value; and output analert signal if the measure related to the leakage rate crosses thethreshold value.
 2. The valve assembly of claim 1, wherein the thresholdvalue is an allowed leakage rate associated with a safety standard. 3.The valve assembly of claim 1, wherein the intermediate volume isdefinable by a user in the field.
 4. The valve assembly of claim 1,wherein the measure related to the leakage rate is identified based atleast in part on atmospheric pressure.
 5. A valve assembly forcontrolling fuel flow to a combustion appliance, the valve assemblycomprising: a valve body having an inlet port and an outlet port, with afluid path extending between the inlet port and the outlet port; a firstvalve situated in the fluid path between the inlet port and the outletport; a second valve situated in the fluid path between the inlet portand the outlet port downstream of the first valve, with an intermediatevolume between the first valve and the second valve defined by the valvebody; a first valve actuator, secured relative to the valve body, forselectively moving the first valve between a closed position, whichcloses the fluid path between the inlet port and the outlet port, and anopen position; a second valve actuator, secured relative to the valvebody, for selectively moving the second valve between a closed position,which closes the fluid path between the inlet port and the outlet port,and an open position; an intermediate pressure sensor in fluidcommunication with the intermediate volume between the first valve andthe second valve for sensing a measure that is related to a pressure inthe intermediate volume; a controller operatively coupled to the firstvalve actuator, the second valve actuator and the intermediate pressuresensor, the controller configured to: identify a predetermined duration;close both the first valve via the first valve actuator and the secondvalve via the second valve actuator; identify a measure related to aninitial pressure in the intermediate volume of the valve body; determinea threshold value based at least in part on both the measure related tothe initial pressure and the identified predetermined duration; identifya measure that is related to the pressure in the intermediate volume,and compare the identified measure related to the pressure in theintermediate volume during the predetermined duration to the determinedthreshold value; and output an alert signal if the measure related tothe pressure in the intermediate volume during the predeterminedduration crosses the threshold value.
 6. The valve assembly of claim 5,wherein the predetermined duration is one of a test duration and aduration less than the test duration.
 7. The valve assembly of claim 5,wherein the intermediate pressure sensor senses the measure related tothe initial pressure before both the first valve and the second valveare closed, after both the first valve and the second valve are closed,or both.
 8. The valve assembly of claim 5, wherein the valve assemblyfurther includes an upstream pressure sensor situated upstream of thefirst valve, wherein the upstream pressure sensor identifies the measurerelated to initial pressure in the intermediate volume of the valve bodybefore both the first valve and the second valve are closed, after boththe first valve and the second valve are closed, or both.
 9. The valveassembly of claim 5, wherein the threshold value is determined based atleast in part on the measure related to the initial pressure in theintermediate volume of the valve body, the identified predeterminedduration, and an acceptable leakage rate.
 10. The valve assembly ofclaim 9, wherein the acceptable leakage rate is adjustable from a firstvalue to a second value in the field.
 11. The valve assembly of claim 5,wherein the predetermined duration is adjustable from a first value to asecond value in the field.
 12. The valve assembly of claim 5, whereinthe controller is further configured to disable operation of the valveassembly in response to the alert signal.
 13. The valve assembly ofclaim 12, wherein disabling operation of the valve assembly includesclosing both the first valve and the second valve.
 14. The valveassembly of claim 5, wherein the measure related to the initial pressurein the intermediate volume of the valve body is sensed by an upstreampressure sensor situated upstream of the first valve with one or more ofthe first valve and the second valve in the closed position.
 15. Thevalve assembly of claim 5, wherein the measure related to the initialpressure in the intermediate volume of the valve body is sensed by theintermediate pressure sensor with the first valve in the open positionand the second valve in the closed position.
 16. A method of performinga valve proving test of a gas valve assembly, the gas valve assemblyincluding a controller, a first valve, a second valve downstream of thefirst valve, and an intermediate volume pressure sensor, where theintermediate volume pressure sensor is positioned to sense a pressure inan intermediate volume between the first valve and the second valve, themethod comprising: closing both the first valve and the second valve;identifying a measure that is related to a pressure change rate in thepressure sensed by the intermediate volume pressure sensor; identifyinga measure that is related to a leakage rate based at least in part onthe measure that is related to the pressure change rate in theintermediate volume and a measure that is related to the volume of theintermediate volume; comparing the measure related to the leakage rateto a threshold value; and outputting an alert signal if the measurerelated to the leakage rate crosses the threshold value.
 17. The methodof claim 16, wherein the threshold value is an allowed leakage rateassociated with a safety standard.
 18. The method of claim 16, whereinthe volume of the intermediate volume is definable by a user in thefield.
 19. The method of claim 16, wherein the measure related to theleakage rate is identified based at least in part on atmosphericpressure (P_(atm)).
 20. The method of claim 16, wherein the measurerelated to the leakage rate is identified based on the equationQ_(calculated)=dP/dt*V/P_(atm)*3600.